Applications of robots in the energy and natural resources sector

As unmanned systems evolve from mere scientific experiments into essential industrial tools, comparable to regular screwdrivers, their design is increasingly focused on reliability and endurance. This allows them to operate in demanding environments such as chemical plants, power stations and oil rigs, facing environmental and impact risks.

In this context, Spain-based Robotnik has developed the RB-WATCHER, an advanced system that integrates a wide variety of sensors into a robust body. This design allows it to navigate and inspect industrial installations, both indoors and outdoors, minimising the risk of adverse environmental conditions and reducing failure points.

The RB-WATCHER has dimensions of 904 x 731 x 614 mm and weighs 73 kg unladen and can carry up to an additional 50 kg. It travels at a speed of 2.5 m/s (9 km/h) in typical industrial inspection missions and offers an operating range of five hours, thanks to its electric four-wheel drive (4WD). The platform is IP54-rated, which means it is protected against limited ingress of dust and low pressure water.

Thanks to more than two decades of experience in the development of robotic systems, Robotnik has worked on the creation of robots and mobile manipulators for various professional applications. As a result of this experience and the design of the RB-WATCHER the company has managed to position itself in the market with a high-end industrial inspection robot, already used by several customers and with several more in the process of adoption.

The development of the RB-WATCHER dates back to 2018 as an evolution of the RB-SUMMIT, a robotic platform that Robotnik designed and continues to market for more than 15 years as a multipurpose unmanned ground vehicle (UGV).

‘We were looking for new use cases with higher demand and we detected a growing interest in the energy sector in Spain, especially in the autonomous inspection of electrical infrastructures,’ explains Marta Millet Pascual-Leone, business development manager at Robotnik.

‘During a long period of consultation with our customers, we tested different robot configurations and combinations of sensors and subsystems, including various types of LiDAR, cameras, GNSS technologies and autonomous navigation algorithms. This allowed us to define the ideal needs of the robotic platform, not only for that specific case, but also for general inspection applications.

The development process included important learnings, such as the need to ensure electrostatic safety in electrical environments, minimise vibrations and maximise environmental resistance both indoors and outdoors. For components exposed outside the robot’s IP54 housing, finding weatherproof options without driving up costs was a key challenge for Robotnik’s engineers.

While indoor navigation seemed to be the biggest challenge for the software team, outdoor operation also presented difficulties due to factors such as changing weather conditions, which could generate unpredictable interference, or the presence of concrete and metal structures, which affected the GNSS signal and other sensors.

To overcome these challenges, Robotnik developed a prototype of the RB-WATCHER, which was successfully deployed and tested by its customers. Thanks to its ability to operate reliably in harsh industrial environments, a renewal contract was signed that included the purchase of ten additional units.

‘With this data and the confidence gained, we were able to profile the AMR in a way that allowed us to adapt the design for other similar sectors and industries, such as inspection at other energy companies, airports and industrial facilities,’ adds Millet.

“Robotics in the oil and gas industry requires high levels of stability and reliability to perform inspection missions. Thus, the Uncrewed Systems Technology publication devotes a section to the components of an inspection robot, which are fundamental to understanding its functionality in robotic applications in the energy sector.”

As Millet explains, the EO/IR (electro-optical infrared systems) system on top of the RB-WATCHER is only used for inspection missions if the end user values it, and is never necessary for navigation.

The choice of inspection cameras was based primarily on their size; too large a sensor on top of the UGV would have generated vibrations and inertia that would affect both the stability of the captured images and the stability of the robot’s own motion.

‘Of course, it was also essential that the gyro system had very precise pan and tilt control for stable, shake-free images,’ adds Millet.

Opting for a high-quality thermal camera was a key aspect, as infrared photography was (rightly) considered to be the most important part of the robot’s inspection work. Thermal imaging can detect cracks, degradation and hot spots in industrial assets with a level of detail that optical cameras cannot match.

During the engineering process, ensuring constant data output and communication between the cameras and the UGV was essential, as this is the first step in achieving real-time monitoring and analysis of the inspection information generated.

A series of LED lights integrated into the platform where the gyro system is located provides visibility to the optical camera in low light conditions. In addition, it emits situation-specific light signals, such as load indications or fault detection. It also helps to alert nearby personnel to the robot’s presence, reducing the risk of collisions in areas with high pedestrian or vehicular traffic. Robotnik tested different LED models for electromagnetic compatibility, software compatibility and electrical stability before selecting the ideal components.

In addition to the two cameras and LEDs, the RB-WATCHER also features a microphone, a key tool for audible detection of gas leaks, electrical system failures and other critical anomalies in industrial environments.

A loudspeaker is also installed for the AMR operator or crew to transmit audible warnings when appropriate.

‘We also needed their firmware to be compatible with our software, including the ability to trigger the microphone or speaker from the operator’s HMI with good consistency and low latency. This includes the ability for users to trigger automatic audio recording when there are indications that a machine or infrastructure element is failing. So it was only after testing many systems that we found good solutions for both’.

Robotics in the oil and gas industry, as well as in the energy sector in general, is an important aid to providing a safer, more cost-effective and efficient working environment.

Robots such as the RB-WATCHER drive safer and more accurate processes for high-risk environments, reducing human exposure and avoiding failures that can be prevented with stable inspection.

Thanks to recent advances in sensors, navigation and software, the oil and gas industry can respond to the growing demand for increased productivity and safety. Robotics has established itself as a key solution optimising operations, reducing costs and minimising worker exposure to high-risk environments.